Transient-free synchronous electrical power machine

ABSTRACT

Proximity switches and circumferentially movable stator windings allow a motor-generator to simultaneously sense and switch from a synchronous motor position to a synchronous generator position. This mechanism replaces the conventional separate sensing and switching of motor-generator functions. Automatic rotational repositioning of the stator maintains constant voltage and prevents the generation of transient voltages or harmonics. The stator flux leads the rotor magnetic flux slightly in an import power or motor position, creating a torque on the rotor and a counter torque on the stator reacted by the fixed casing of the apparatus. As the stator field weakens due to a failure of the normal power supply, the counter torque also weakens and the stator windings are biased to begin to turn with the rotor until the rotor and stator fields are in step, i.e., when virtually no current is generated or consumed or until a full export power or generator position is reached. The dynamic stator may also be used in electric motors or generators to filter or cushion variations in the power supply or in the load.

This is a continuation application of Ser. No. 07/903,10, filed Jun. 23,1992, now U.S. Pat. No. 5,311,062, a continuation-in-part of co-pendingapplication Ser. No. 680,543 filed Apr. 4, 1991, now abandoned.

FIELD OF THE INVENTION

This invention relates to rotating electric machines and to electricpower generation and use. More specifically the invention relates to aheavy-duty synchronous motors and synchronous generators.

BACKGROUND OF THE INVENTION

Heavy duty electrical power motors and generators used to drivemachinery as primary or back-up electrical power source, andparticularly synchronous electrical motors and generators are subject tosudden variations in the magnetic flux between the rotor and statorwindings everytime there is a phase shift between the rotor armatureflux and the stator armature flux. Such a phase shift occurs upon suddenincrease or decrease in the mechanical load or in the power fed to asynchronous motor, and sudden increase or decrease in the electricalload or the torque applied to a synchronous generator.

The sudden phase shift can produce substantial voltage transients thatcannot be tolerated by a critical load of a generator, or that can befed back on the line power to a motor.

Sensitive loads such as data processing equipment and medicalinstruments must nowadays be protected by heavy, cumbersome and costlyfiltering and regulating devices. Utilities must protect theirinstallations against power surges fed back by a motor suddenly turnedinto a generator by use of circuit breakers and other safety deviceswhich increase the risk of blackouts.

The instant invention results from an attempt to limit these undesirablespurious lines transients by attacking the problem at its source, i.e.inside the synchronous power machinery.

Uninterruptible power supply systems are provided for switching from anormal line supply of electric power to a standby or backup power supplyin the event of interruption, failure or inadequacy of the normal powersupply. For true uninterruptible power, the switching must be virtuallyinstantaneous, and for cyclic power, without any change in phase,frequency or voltage.

Uninterruptible power supplies may require a transitional supply ofpower, such as a flywheel, to carry the load until the standby source ofpower can be brought up to speed and switched on-line. The flywheel mayhave to be combined with fast acting power loss sensors and solid stateswitches in order to keep flywheel weight and size reasonable. Anexample of a fast acting switch is shown in U.S. Pat. No. 4,827,152.

Many of the current uninterruptible power supplies may accomplish theswitching quickly, but not without a significant flywheel weight.Depending upon rotating mass requirements, the flywheel may be aseparate structure or incorporated in the construction of the motor,shaft, or rotor. For critical loads where even a small change infrequency can cause problems, flywheel size requirement may becomeunpractical. The flywheel large spinning mass also creates problems instartup and performance when acceleration or deceleration of thespinning mass is required.

Even fairly massive flywheels and fast acting switches may have to besupplemented by spinning stand-by, dual drives, and other devices. Anexample of additional devices required is shown in U.S. Pat. No.3,458,710.

Holding cyclic electric power frequency and phase within tolerances forthese additional devices for critical loads has also been a problem.Frequency changers (e.g., coupled rotating units at different phases atany one rotary position) and other Complex devices have been used tocontrol critical frequency and phase outputs from rotating electricmachines for critical applications.

There is a need for a simpler and more effective power backup systemwhich can instantaneously detect any failure of the line power andsynchronously switch to a stand-by power supply without resorting tomassive kinetic energy storage device or complex phase and frequencymaintenance circuitry.

SUMMARY OF THE INVENTION

The principal and secondary objects of the invention are:

to suppress spurious transients in synchronous motors and generators dueto sudden changes in the power supply or load,

to automatically correct transitory phase shift between rotor and statorfluxes that may be caused by such changes,

to provide a quick reacting electric power sensor/switch to backup powersupply; and

to provide the backup power at virtually the same phase and frequencywithout the need for complex control circuitry or significant flywheelmass.

These and other objects are achieved by dynamic stator windings that arefree to rotatively oscillate around the rotor over a limited range inresponse to variations and reversal of magnetic forces between the rotorand stator as a result of sudden changes in power supply or load. Thisallows the rotating electric machine to continuously adjust or filtertransients in mechanical or electrical inputs. When combined withproximity switches the dynamic stator causes a synchronous motor to turninto a synchronous generator upon loss of power. The repositioning ofthe stator windings signals changes in the operating conditions of themachinery; and simultaneously switches functions to maintain constantvoltage and prevent the generation of transient voltages or harmonics.

In an import power position of the stator windings, the motor-generatoracts as a motor driven by a normal electric power supply. The statorflux leads the rotor magnetic flux slightly, creating a torque on therotor and a counter-torque on the stator. As the stator field weakensdue to a loss or inadequacy of the line power, the counter torque alsoweakens, and the stator windings begins to turn with the rotor until therotor and stator fields are in step, i.e., when virtually no current isgenerated or consumed to produce useful work. The motion of the statorcan be used to trigger a switch to an alternate source of power withoutany transients being generated.

As the stator continues to rotate, the stator flux begins to lag therotor magnetic flux slightly, allowing the motor-generator to generateor export electric power. The dynamic or floating stator can be allowedto adjust itself automatically to the proper flux angle between therotor and stator. This effectively isolates the output electric powerfrom variations in the electric input. It also lets the apparatusautomatically adjust the power factor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a floating stator motor-generatorin a preferred uninterruptible power supply system;

FIG. 2 is a perspective view of power back-up and regulating motor andgenerator installation;

FIG. 3 is an end view of the motor-generator taken along line 3--3 ofFIG. 2;

FIG. 4 is an end view of a motor-generator having an alternativefloating stator mechanism;

FIG. 5 is a detail section of the alternative floating stator mechanismshown in FIG. 4;

FIG. 6 is a schematic illustration of a second uninterruptible powersupply system for less critical electric loads; and

FIG. 7 is a schematic illustration of a third power supply system,

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawing, there is illustrated in FIG. 1 asynchronous motor-generator 2 which acts as the key component of aback-up power supply system 1 to a critical load 10. One end of theshaft 3 of the motor-generator 2 is connected to a generator 4, Aflywheel 6 is mounted on the opposite end of the shaft 3 which isengaged by a clutch 7 coupled to a thermal engine 5.

The motor-generator 2 is supported above ground at both ends of theshaft 3 by braces 13, 14. The casing 15 and the motor-generator statormounted therein are allowed to partially rotate around the shaft 3 androtor mounted upon it.

During non-critical periods of operation when the load 10 can toleratevariations in the power supply or even temporary failures of the powersource, only the utility switch 12 is closed and the load 10 receivesits power from the utility power line 9 through the electrical governorunit 10a. Under more demanding conditions during which transients in thepower supply to the load 10 must be avoided, the motor-generator switch8 and the generator switch 11 are also closed. The motor-generator 2 isenergized by the utility power source 9 and acts as a synchronous motordriving the generator 4. The generator supplies power to the electricalload 10 through the governor control unit 10a, either alternatively orconcurrently with the power line. The load 10 can be completelyimmunized against transients on the power line 9 by opening the utilityswitch 12, and leaving the generator 4 to supply the necessary power.

In a critical situation where failure of the power supply to the load 10must be avoided, the thermal engine 5 is kept running, and the clutch 7is engaged upon failure of the utility power source 9. Themotor-generator switch 8 is opened. The thermal engine 5 begins drivingthe motor-generator 2 and the generator 4, assures a continuous,transient-free supply of electrical power to the load 10. Due to theparticular arrangement of the motor generator 2 according to theinvention, the switch over from the electrical power derived from theline 9 to the mechanical power provided by the thermal engine is alsofree of transients, voltage drop, frequency change, or phase shift. Theline power can be reinstated by closing the motor-generator switch 8 anddisengaging the clutch 7. The embodiment of the invention accomplishesthis reversal of power supply without any detrimental effect on thepower supplied to the load 10 by the generator 4.

Even a failure of the generator 4 can be palliated without interruptionor deterioration of the power supplied to the load 10 by opening thegenerator switch 11 and closing the motor-generator switch 33.

It can be seen that changes in the source of the power drawn by the load10 are accomplished not by direct switching of the load but by drivingthe motor-generator 2 either electrically from the power line 9 ormechanically with the thermal engine 5. Load 10 is insulated from thisswitch of power by the generator 4 and by the motor-generator 2.

The thermal engine 5 may be an internal combustion engine, or a gas orsteam turbine. An auxiliary hydraulic motor may be used to boost thepower of the thermal engine to bring the flywheel to speed. The clutch 7is preferably of the over-running type which disengages immediately whenthe motor-generator over-runs the thermal engine. Allowing the stator ofthe motor-generator 2 to circumferentially move during power switch-overwas found to yield many advantages. It is also advantageous to allow fora limited rotational movement of the stator in the generator 4 as wellas in the motor-generator 2.

As previously disclosed in my U.S. Pat. No. 4,827,152, the movement of aloosely supported stator of a synchronous motor-generator can be sensedas an indication of a change of the supply voltage. This change can besensed by a motion detector 32, and used to trigger a switch to analternate power. The rotational movement of the stator may be allowedthrough diverse mounting schemes.

In the earlier described situation, when the load 10 is powered fromboth the utility power source 9 and by the generator 4, the load sharingcontrols of the electrical governor unit 10a are preferably set to drawabout 90 percent of the necessary power from the generator 4 and thebalance from the power line source 9. Upon failure of either the powerline source 9 or the backup system, the switching from either or bothpower sources to the alternate, or to a single source, is also regulatedby the dynamic mounting of the stator of the motor-generator 2 as willbe explained below.

FIGS. 2 and 3 illustrate a convenient way for dynamically supporting thestator of the motor-generator 2, which way is particularly adapted foruse with conventional types of motor-generators in which the stator iswelded to the inside of the casing.

While the casing of the generator 4 is bolted to the raised portion 16aof the slab 16, the casing 15 of the motor-generator 2 is floatinglysuspended above the lower portion 16b of the slab. The forward end 3a ofthe shaft 3 which also supports the flywheel 6 and connects to theclutch 7, is supported by a first brace 13 through bearing 13a. Theheight H at which the shaft 3 is supported above the lower portion 16bof the slab substantially exceeds the distance from the shaft 3 to theunderside of the casing 15. A second brace 14 supports through bearing14a the opposite end 3b of the shaft 3 which connects to the shaft ofthe generator 4. This second brace may be omitted if the internalbearings of the generator 4 can withstand the added weight of themotor-generator 2.

The vertical clearance C between the casing 15 and the slab 16b mustallow for rotational excursion of the casing around the shaft 3. Atypical four-pole machine requires a rotational movement of the statorover 22.5 degrees in either direction. This corresponds to a 90 degreeelectrical phase shift. Accordingly, the minimum arcuate travel A of thestator is based on the number N of poles according to the followingformula:

    A=180/N degrees

The maximum range of rotation allowed should be slightly less than a180-degree phase shift, for instance: 350/N degrees. This limit isestablished by placing stop-bumpers 17, 18 at appropriate heights on thesurface of the slab 16b below the outer edges 19, 20 of themotor-generator foot.

Another way to implement the dynamic suspension of the synchronousmotor-generator stator is illustrated in FIGS. 4 and 5. Instead ofwelding the stator to the inside of the casing as is commonly done, thestator 21 is supported by a series of roller bearings 22. The carriage23 of each roller bearing is welded to the stator 21, and the rollers 24ride against the inner wall 25 of the circular casing 26. The rotationalexcursion of the stator 21 around the rotor 27 is stopped by aprojection 30 on one of the roller bearing carriage 23 bumping againststops 28, 29 mounted on the inside surface 31 of the casing 26.

In this embodiment, the casing 26 is bolted to the supporting slab in aconventional fashion.

The advantageous operation of the dynamic stator arrangement of thesynchronous motor-generator can be best understood by considering themovement of the stator during the change from the motor to the generatormode and vice versa.

When the motor-generator 2 of FIG. 1 is operating as a synchronous motorenergized by the line power source 9, the stator magnetic flux leads therotor magnetic flux. The resulting torque applied against the statorcircumferentially forces the stator to its maximum allowed excursionopposite the rotational direction of the rotor.

Upon failure of the line power, the stator field disappears and thestator moves in the direction of the rotor. At this point, both statorand rotor fields are in step, and no current is generated. The sensor 32detects the loss of power,,and gives the signal to disconnect the line 9and engage the clutch 7.

The progressive rotational movement of the stator during themetamorphosis of the machine from a synchronous motor to a synchronousgenerator delays the effect of the switch-over and consequentlymaintains, for a short time, the torque that the motor-generator appliesto the generator 4 until the mechanical power of the thermal enginetakes over. There is no abrupt drop of voltage or frequency, only a 90degree phase shift in the power coming out of the generator. Thisphenomenon supplements the effect of the flywheel 6, therefore reducingits mass requirement, and in some applications, resulting in itscomplete elimination.

The reverse of the above-described phenomenon takes place inapplications where the motor-generator 2 reverts from its role as asynchronous generator to a motor. When the machine is working as asynchronous generator, the stator magnetic flux lags the rotor magneticflux. As the mechanical drive is being replaced by the electrical powerfrom the power lines the progressive recoil movement of the statormaintains the power output allowing a smooth transition to the alternatepower source.

Theoretically the synchronous motor rotating magnetic field should speedup slightly in order to have a transition-free change-over from motor togenerator but this is not possible because it is the stator magneticflux that generates that field, and when the stator magnetic fluxweakens or disappears, the field automatically slows down causing hightransient voltages.

The free movement of the stator causes a corrective magnetic flux changebetween the stator and rotor fields. The stator movement is natural andis caused by the change of torque between the stator and the rotor. Inthe case of a motor, the stator torque is counter to the rotation fieldtorque. In the case of a generator, the stator torque and the shafttorque are in the same direction. Due to the relationship betweentorque, power and supply voltage, any change in power supply voltagewill have a direct effect in the stator/rotor torque causing the statormovement to either absorb or generate a corrective amount of power.

An alternative uninterruptible power supply system for less criticalloads is shown in FIG. 6. The motor-generator 2 is brought up to speedby the thermal engine 5 and synchronized with the utility power 9. Asthe utility switch 12 and the motor-generator switch 8 are closed, thethermal engine 5 may be shutdown and clutch 7 disengaged, allowing themotor-generator 2 to act as a synchronous condenser-filter. The spinningflywheel 6 and rotor within the motor-generator 2 filters or smoothsutility power transients and stabilizes voltage. Excess power can beabsorbed virtually instantly by a change in position of the dynamicallymounted stator of the motor-generator 2. Conversely, a nearlyinstantaneous shift in stator position regulates the power as requiredby variations of the load 10. Upon a voltage drop beyond a thresholdlimit or loss of utility power 9, utility switch 12 opens, thermalengine 5 starts, and clutch 7 engages to supply the load 10. If the loadis more sensitive to loss of power than excess voltage such as utilitypower spikes, the thermal engine 5 may be kept running while line power9 is being used to supply a portion of the load power continuously andto provide even faster and smoother switching of power sources.

Electrical switches can also be controlled by other devices in lieu orin addition to the one sensing the motion of the dynamic stator. Sensor34 is shown as a tachometer which can also provide control signals foropening or closing electrical switches, in addition to or in lieu of asensor tracking the motion of the stator of the motor-generator.

A conventional standby generator is normally isolated through amechanically interlocked transfer switch. During utility failure, theload is switched from utility to standby; then switched back when normalpower is restored. Each failure causes two interruptions to the load.Critical power users such as hospitals require that their emergencystandby generators be exercised under full or partial loads at leastonce every two weeks. This can only take place during non-critical timessince normal power has to be interrupted to exercise the system.

A standby power system, according to the invention allows the user toexercise the back-up power at any time. The motor-generator 2 is broughtup to synchronous speed via a thermal engine 5, and synchronized to theutility 9. Once the generator breaker 8 is closed the engine comes tostop and is disengaged through an over-running clutch 7.

The synchronous machine 2 becomes a synchronous motor (or synchronouscondenser), corrects power factor, and helps maintain constant voltage.To exercise the power back-up system, it suffices to start the engine.When the over-running clutch mechanically engages the motor shaft, thestator no longer creates torque, and therefore it turns in the directionof the shaft rotation until it comes up to the stator stop position atwhich time the machine becomes a generator. The utility breaker 12 isautomatically opened and the load 10 is now on emergency power. When theexercise period is over, a relay closes the utility breaker 12 at theproper synchronous time, the engine stops and as the stator flips backin a direction opposite the shaft rotation, the generator then becomes asynchronous condenser.

FIG. 7 illustrates another embodiment for supplying uninterruptiblemechanical power and/or electric power. The thermal engine 5 can be usedto start (i.e., soft start) the mechanical load 35 until the rotationalspeed of shaft 3 allows the motor-generator 2 to be synchronized withthe utility power 9. Normal operation would have the utility switch 36and motor-generator switch 37 closed, the thermal engine 5 shutdown andthe clutch 7 disengaged. The motor-generator dynamic stator provides acushion, filtering out transients that might otherwise be transmitted tothe mechanical load 35. The mechanical load 35 may be pump orcompressor, such as one that must supply a constant stream of fluid to acritical process.

When utility power is lost or inadequate, the dynamic motion of themotor-generator stator signals the power failure and simultaneously themotor-generator 2 begins to generate power. The power failure indicationtriggers the start of the thermal engine 5 to fully supply mechanicalpower to the load 35. If the utility power 9 can be isolated, and thethermal engine 5 and motor-generator 2 sized accordingly, mechanical andelectric power can be simultaneously supplied. The engine can also bekept running during the time line power 9 is available to completelyprotect the electrical load against any switch-over transient. Thesystem can also provide peak shaving capability, that is, the mechanicalload 35 may be driven in a cogeneration mode by the thermal engine 5during peak time periods in order to reduce utility charges. Themotor-generator 2 will correct for power factor and other unwantedelectric power conditions.

The unique peak shaving ability is provided by the limited movement ofthe stator. For example, under normal conditions the motor-generator 2driving a compressor 35 imports 300 amps at 600 volts. When the naturalgas engine 5 is started during peak periods it provides some of therequired shaft driving torque. During this time the stator will losesome of its counter torque and will move toward the transition orgeneration position depending on how much torque the engine issupplying. The engine power output can be preset through an electricgovernor import-export module. If the governor were set to 80% enginepower, the synchronous motor would only import 60 amps during the peakshaving mode.

The many advantages of the present invention include providing cushionedmotor to generator or generator to motor transitions, providing asynchronous motor-generator in a single machine, reducing or eliminatingthe need for reduced voltage or full voltage starters, eliminatingelectrical and mechanical transients, providing soft starts, providing acontinuous transition between export and import electrical conditions,avoiding switching and switch transients, acting as a synchronouscondenser to correct power factor and stabilize voltage, allowing two ormore sources to drive the rotating unit, and supplying emergency,peaking, and uninterruptible electrical and mechanical power.

While the preferred embodiments of the invention have been described,modifications can be made and other embodiments may be devised withoutdeparting from the spirit of the invention and the scope of the appendedclaims.

What is claimed is:
 1. In an electrical alternating power unit wired tomaintain supply of power to at least one load upon lapse of anelectrical power source, said unit including a synchronous electricalpower machine comprising:a synchronous motor having a stator windingenergized by said power source, an axial shaft and a rotor windingmounted on said shaft; and an electrical generator driven by said shaft;an improvement which comprises:means for allowing unrestrainedrotational movement of the stator winding around the shaft in responseto variations of said power source, over an arc limited to maintainsynchronous operation of said motor.
 2. The improvement of claim 1,wherein said means for allowing comprises means for letting said statorwindings rotate over an arc of no less than 180/N degrees and no morethan 350/N degrees, where N is the number of poles of said motorwindings.
 3. The improvement of claim 2, wherein said means for allowingcomprises:said synchronous motor having:a casing resting over asupporting surface; said rotor winding comprising N poles; and means forrotatively supporting said stator winding within said casing and forallowing unrestrained movement of said stator winding about an axiscoincident with said axial shaft over an arc of at least 180/N degreesand no more than 350/N degrees during continuous, synchronous operationof said machine and in response to variations in torque between saidrotating armature and said stator resulting from variations in saidpower source and in loads created by said generator.
 4. The improvementof claim 3, which further comprises means for connecting anddisconnecting said electrical power source; andmeans for connecting anddisconnecting a mechanical power source to and from said synchronousmotor.
 5. The apparatus of claim 4, wherein said mechanical power sourcecomprises a thermal engine; andmeans responsive to a failure of saidpower source for driving said axial shaft with said engine.
 6. Theimprovement of claim 5, wherein said means for driving further comprisesmeans for sensing a rotational movement of said stator; andmeans forconnecting and disconnecting said electrical power source and engine inresponse to said means for sensing.
 7. A self-adjusting electrical loadfor regulating and filtering an alternating electrical power sourcewhich comprises:a synchronous motor having a stator winding energized bysaid power source, an axial shaft and a rotor winding mounted on saidshaft; and means for allowing unrestrained rotational movement of thestator winding around the shaft in response to variations of said powersource, over an arc limited to maintain synchronous operation of saidmotor.
 8. The apparatus of claim 7, wherein said means for allowingcomprises means for letting said stator windings rotate over an arc ofno less than 180/N degrees and no more than 350/N degrees, where N isthe number of poles of said motor windings.
 9. An uninterruptibleelectrical power supply system immune to lapses and variations of autility power source for supplying continuous alternating power to acritical electrical load, said system comprising:a synchronousmotor-generator having a stator winding connectable to said utilitypower source, an axial shaft and a rotor winding mounted on said shaft;means for allowing unrestrained rotational movement of the statorwinding around said shaft in response to variations of said powersource, over an arc limited to maintain synchronous operation of saidmotor; a rotating mechanical engine; means for alternately running saidmotor-generator as a generator driven by said mechanical engine, and asa motor powered by said utility power source; and means for alternatelyconnecting said critical load to said motor-generator when saidmotor-generator operates as a generator, and to said utility powersource when said motor-generator operates as a motor; means for sensinga rotational movement of said stator winding when said motor-generatoroperates as a motor; and means responsive to said means for sensing forswitching said means for alternately running and for alternatelyconnecting.
 10. The system of claim 9, wherein said means foralternately driving comprise a clutch between said mechanical engine andsaid motor-generator.
 11. The system of claim 10 which further comprisesa mechanical load driven by said shaft.
 12. An uninterruptibleelectrical power supply system immune to lapses and variations of autility power source for supplying continuous alternating power to acritical electrical load, said system comprising:a synchronousmotor-generator having a stator winding connectable to said utilitypower source, an axial shaft and a rotor winding mounted on said shaft;an electrical generator driven by said shaft; means for allowingunrestrained rotational movement of the stator winding around the shaftin response to variations of said power source, over an arc limited tomaintain synchronous operation of said motor; a rotating mechanicalengine; means for alternately running said motor-generator as agenerator driven by said mechanical engine, and as a motor powered bysaid utility power source; and means for connecting said critical loadto said generator; means for sensing a rotational movement of saidstator winding when said motor-generator operates as a motor; and meansresponsive to said means for sensing for switching said means foralternately running.
 13. The system of claim 12, wherein said means foralternately driving comprise a clutch between said mechanical engine andsaid motor-generator.
 14. The system of claim 13 which further comprisesa flywheel mounted on said shaft.